Windproof and water resistant composite fabric with barrier layer

ABSTRACT

A stretchable, drapable, windproof, water resistant and water vapor permeable composite fabric including an inner layer of fabric formed from an essentially hydrophobic material rendered hydrophilic having a raised inner surface and a plain outer surface, a barrier means including a hydrophilic barrier layer and an outer layer of fabric. The barrier is constructed to allow water vapor molecules to travel therethrough, but restricts the passage of wind and liquid water. The water vapor is transported to and travels through the barrier to the outer fabric layer where it is removed to the environment.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 07/788,913,filed on Nov. 7, 1991 entitled WINDPROOF AND WATER RESISTANT COMPOSITEFABRIC WITH BARRIER LAYER, now U.S. Pat. No. 5,204,156, which is acontinuation-in-part of U.S. patent application Ser. No. 07/468,027filed on Jan. 22, 1990, now U.S. Pat. No. 5,126,182, which itself is acontinuation-in-part of U.S. patent application Ser. No. 07/422,850filed on Oct. 17, 1989, now abandoned.

BACKGROUND OF THE INVENTION

This invention relates generally to a clothing material and, inparticular to a drapable, stretchable, windproof and water resistant,water vapor permeable, composite fabric that can be used as outerwear.

Treatments to render fabrics wind and water resistant have been knownfor many years. However, it has been difficult to create fabrics whichare suitable for apparel use and which are windproof, water resistantand water vapor permeable. It has also been difficult to create fabricsthat are both water vapor permeable and wind resistant. In particular,it has been difficult to create a soft, stretchable, drapable,breathable, wind and water resistant fabric.

Conventional double-faced raised knit fabrics are porous and thus arenot effective in sheltering the wearer from wind. In the past, a rubberlayer has been adhered to a fabric substrate to impart wind andwaterproof qualities and the exposed surface of the rubber layer wasflocked. Foamed adhesives have been used to adhere layers of flock inupholstery fabrics. These fabrics, however, have generally been formedusing an open weave fabric, such as Osnaburg, as a fabric substrate anddo not have the degree of stretchability and drapability required forapparel fabrics.

U.S. Pat. Nos. 4,308,303 to Mastroianni and 4,353,945 to Sampson teachflocked, foam coated, fibrous reinforced, water vapor permeablebacterial barriers for forming surgical drapes and gowns and similararticles. The barriers include a microporous polyolefin film coated witha foam latex polymer upon which a layer of fibers is flocked. Thebarriers, however, are not suitable for apparel use since the flock isadhered to a polyolefin film, not a fabric. Such materials are also notfully suitable for most outerwear applications.

Previously, a drapable, windproof, water resistant and water vaporpermeable composite fabric has been formed by dispersing a thin layer offoamed adhesive between a fabric substrate and a layer of flockedfibers. The pores of the foamed adhesive are formed to be large enoughto allow water vapor molecules to pass through, but are too small toallow air or liquid water molecules to pass through, except underpressure. This construction can render the fabric wind and waterresistant, but it is neither sufficiently stretchable or drapable forapparel use. In addition, as the wind and water resistance is improved,the water vapor permeability decreases. Thus, it has proved not possibleto achieve the desired level of water vapor permeability using thisfabric construction technique. Further, for some applications, a flockedouter surface is not satisfactory.

Accordingly, it is desirable to provide an improved windproof, waterresistant and water vapor permeable fabric which eliminates the problemsassociated with prior art fabrics and to provide a novel, soft,stretchable, drapable water vapor permeable, windproof and waterresistant composite fabric.

SUMMARY OF THE INVENTION

Generally speaking, in accordance with the invention, a drapable,stretchable, windproof, water resistant, water vapor permeable compositefabric is provided. The composite fabric includes an inner fabric layer,a barrier layer such as a hydrophilic polyurethane barrier thereon andan outer fabric layer suitable for exterior use. The barrier isconstructed to prevent air and water droplets from passing through thefabric layers while allowing water vapor to travel therethrough. Thisrenders the fabric windproof, yet breathable and water resistant.

The inner fabric layer may be rendered hydrophilic to provide moisturetransport by wicking moisture away from the body. The inner fabric has aknit construction and may have a raised surface facing the body and aplain surface facing the barrier. The plain surface is attached to thebarrier.

The barrier layer may be non-porous and hydrophilic or micro-porous andhydrophobic or any combination thereof. If the barrier is non-porous andhydrophilic, moisture vapor next to the body is transported to andtravels through the barrier by an absorption-diffusion-desorptionprocess to the outer fabric layer where it is removed to theenvironment. If the barrier layer is micro-porous and hydrophobic,moisture vapor next to the body is transported to and travels throughthe barrier's micro-pores to the outer fabric layer where it is removedto the environment.

The outer fabric should be suitable for apparel use. It, like the innerlayer, has a knit construction and may be rendered hydrophilic.

The composite fabric according to the invention can be manufactured byforming the barrier on a carrier and then transferring the barrier fromthe carrier to either or both of the fabric layers and adhering the twofabric layers together.

Accordingly, it is an object of the invention to provide a windprooffabric which is water resistant.

A further object of the invention is to provide a composite fabric whichis insulative against wind chill.

A still further object of the invention is to provide a fabric which iswater resistant.

Another object of the invention is to provide a water resistantcomposite fabric having stretchability and drapability suitable forapparel.

Yet another object of the invention is to provide a fabric which isliquid water resistant and water vapor permeable.

Still another object of the invention is to provide an improvedcomposite fabric which is windproof.

Still another object of the invention is to provide improved outerwearmaterial.

Still other objects and advantages of the invention will in part beobvious and will in part be apparent from the specification.

The invention accordingly comprises the several steps and the relationof one or more of such steps with respect to each of the others, and thearticle possessing the features, properties, and the relation ofelements, which are exemplified in the following detailed disclosure,and the scope of the invention will be indicated in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the invention, reference is had to thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1 is a perspective view of a garment made from a composite fabricconstructed in accordance with the invention;

FIG. 2 is an enlarged partial cross-sectional view taken along line 2--2of the garment FIG. 1;

FIG. 3 is a cross-sectional view of a composite fabric constructed inaccordance with another embodiment of the invention; and

FIG. 4 is a cross-sectional view of a composite fabric constructed inaccordance with another embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Composite fabric material constructed in accordance with the inventionis formed with a first layer of outer fabric material, a windproof andwater resistant barrier thereon and a second layer of inner fabricmaterial applied to the barrier. The barrier is preferably formed ofwater resistant material such as polyurethane and should be made to bebreathable and to act as an air barrier. The breathability can beimparted by forming the layer to have sufficient thinness to permitwater vapor to pass through the layer, as by anabsorption-diffusion-desorption process or by providing the materialwith micro-pores for the passage of said water vapor.

The inner fabric layer may be formed of 100% polyester having a plainsurface and a raised surface, such as a brushed polyester fabric orpolyester fleece material. The 100% polyester inner fabric layer may berendered hydrophilic to promote moisture transport, so that the innerfabric will transport moisture from the body to the plain surface.

The barrier is disposed on the inner fabric. When the inner fabric isconstructed with a plain surface having raised portions extendingtherefrom, the barrier is preferably disposed on the plain surface. Aparticularly well suited barrier is formed from a hydrophilicpolyurethane and may be derived from a solvent based system. Thehydrophilic polyurethane is formed so that moisture will passtherethrough by an absorption-diffusion-desorption process. Such apolyurethane barrier is non-porous and formed so that body moisture willbe transported therethrough, while being sufficiently resistant to thepassage of water droplets. The thickness of the barrier or polyurethanelayer can be selected to balance breathability and degree of waterresistance. In addition, the barrier could be partially hydrophobic, inthat there are fewer pores/mm² than in a true hydrophobic barrier.Therefore, the moisture will pass through the hydrophilic portion of thebarrier by an absorption-diffusion-desorption process and through themicro-pores of the hydrophobic portion.

The barrier layer may be an aromatic or an aliphatic polyurethane andcan contain: a polyfunctional isocyanate to promote cross-linking,melamine to promote adhesion, aliphatic polyamine to catalyze curing anda fluorocarbon resin for water repellency. A microporous film, permeableto water vapor but impervious to liquid water can also be used. Such afilm would be hydrophobic. The barrier layer should be formed to be softand to have the ability to stretch and recover. It should alsopreferably be formed to have the ability to adhere to fabric layerswithout the application of an intervening adhesive. A preferredpolyurethane material is available from UCB Chemical Corp., located inDrogenbos, Belgium.

The outer fabric is disposed on the remaining side of the barrier. Theouter fabric will be hydrophobic or rendered hydrophilic. The outerfabric can be formed of 100% polyester, such as polyester fleece havingterry loop construction, and can have a plain surface with a raisedfabric surface extending therefrom. The outer fabric can also be astretch material. The outer fabric can also be made from acrylic,cotton, nylon, wool, rayon or a combination thereof.

In another embodiment of the invention, a sub-barrier layer is disposedon the desired surface of both the inner fabric and the outer fabric.The two sub-barrier layers are disposed on and adhered to each other, toform the desired barrier layer. In such a case, the sub-barrier layersare preferably joined by heat and/or pressure. The barrier layer orsub-barrier layers can also be adhered with adhesive.

Reference is made to FIGS. 1 and 2 wherein a garment, indicatedgenerally at 10 is depicted. Garment 10 (i.e. a jacket) is made from acomposite fabric in accordance with an embodiment of the invention,indicated generally at 12. Composite fabric 12 includes an inner fabriclayer 16, a first sub-barrier layer 18 thereon, a second sub-barrierlayer 20 thereon and an outer fabric layer 22 on second barrier layer20. Inner fabric layer 16 includes a raised surface 26 and a plainsurface 28. Sub-barriers 18 and 20 are made of polyurethane and arewindproof and water resistant. Outer fabric layer 22 includes a plainsurface 29 and a raised surface 21.

In one method of constructing the fabric, sub-barrier layers 18 and 20are laid on a carrier such as paper (not shown). Sub-barrier layer 18 istransferred from its carrier to inner fabric layer 16 and secondsub-barrier layer 20 is transferred to as its carrier to outer fabriclayer 22. This method, referred to as transfer coating is advantageousbecause it allows for the precise control of barrier weight andthickness and allows the use of thinner and lighter barrier layers.Sub-barrier layers 18 and 20 are then adhered to each other to formcomposite fabric 12.

Inner fabric layer 16 can also be made from acrylic, cotton, nylon,polyester, wool, rayon or a combination thereof. It can be treated toprovide moisture transport to wick the moisture from the wearer andraised surface 26 facing the wearer to plain surface 28. Then, by aprocess of absorption-diffusion-desorption, moisture is transferredthrough sub-barrier layers 18 and 20 to outer fabric layer 22.

In one embodiment, outer fabric layer 22 is a circular weft knitpolyester terry loop fabric. The loop and stitch yarn may be filament orspun. If the loop yarn is filament, it is from about 70 to about 150denier, preferably about 100 denier. If the stitch yarn is filament, itis bettween fraom about 70 to about 100 denier, preferably about 100denier. The fabric layer is from about 0.030 to about 0.30 inches thick,preferably about 0.070 inches thick. However, this fabric layer isdescribed by way of example and not by way of limitation. Outer fabriclayer 22 can be a stretch material, nylon shell material and many othertypes of fabrics. Outer fabric layer 22 may be dyed conventionally with,for example, disperse dyes, and it can be treated to be water repellant.

Referring to FIG. 3, in another embodiment of the invention, adhesive isapplied to the unraised (plain) side of fabric layers 22 and 16 bygravure printing or by another suitable application process to furthersecure barrier layer 18 to inner fabric layer 16 and outer fabric layer22. The adhesive must be discontinuous so as not to interfere with themoisture vapor transport properties of the fabric. Adhesive 15 can be afoamed or unfoamed adhesive, and may be water resistant. Generally, theadhesive is preferably a solvent based polyurethane, such as UcecoatTD9607, manufactured by UCB Chemical Corp.

A composite fabric 40 constructed in accordance with another embodimentof the invention is shown in FIG. 4. Fabric 40 is formed with a firstfabric layer 41 disposed on barrier layer 42 which is disposed on asecond fabric layer 43. Barrier layer 42 should be formed to permitmoisture to pass through by an absorption-diffusion-desorption processor by passage through micro-pores. The materials for forming fabric 40can be the same as those described above, except that fabric 40 includesa single barrier layer.

When composite fabric 12 is used for outerwear, it can provide abreathable fabric which enables water vapor from the wearer to passthrough the fabric which therefore will not trap body moisture. However,it will substantially prevent rain water droplets from reaching thewearer. The result is great comfort. The composite fabric of theinvention can provide water resistance so that the garment can be usedin rainy weather or in snow. Fabric in accordance with the invention canmaximize this characteristic without undue sacrifice of thebreathability or wind resistance of the garment.

While breathable, composite fabric 12 is impervious to moving air.Therefore, whether the wearer is exposed to windy conditions or createsa windy condition by moving rapidly through still air, the wearer isinsulated from the effects of wind chill.

The resultant composite fabric has good drapability, feel and appearancecharacteristics making it particularly suited for garments. It is alsodurable, stretchable and comfortable.

It will thus be seen that the objects set forth above, among those madeapparent from the preceding description, are efficiently attained and,since certain changes may be made in carrying out the above method andin the constructions set forth without departing from the spirit andscope of the invention, it is intended that all matter contained in theabove description and shown in the accompanying drawings shall beinterpreted as illustrative and not in a limiting sense.

It is also to be understood that the following claims are intended tocover all of the generic and specific features of the invention hereindescribed and all statements of the scope of the invention which, as amatter of language, might be said to fall therebetween.

What is claimed is:
 1. A stretchable, drapable, water vapor permeable,windproof and water resistant composite fabric for use in a garmentcomprising:an outer layer of fabric; an inner layer of fabric having araised inner surface and a plain outer surface and formed from anessentially hydrophobic material that has been rendered sufficientlyhydrophilic to permit wicking of moisture from the raised inner surfaceof the inner layer to said plain outer surface thereof; barrier meansfor providing resistance to wind and liquid water while providing forwater vapor transport through absorption-diffusion-desorption includinga hydrophilic barrier layer disposed on and adhered to at least one ofsaid outer surface of said inner layer of fabric or said outer layer offabric; and said other of said outer surface of said inner layer offabric or said outer layer of fabric being disposed on and adhered tosaid barrier means.
 2. The composite fabric of claim 1, wherein saidouter fabric layer is hydrophobic.
 3. The composite fabric of claim 2,wherein said outer fabric layer has a raised outer surface and a plaininner surface to which said barrier layer is adhered.
 4. The compositefabric of claim 2, wherein said outer fabric is an essentially flatshell material.
 5. The composite fabric of claim 1, wherein said outerfabric layer is treated to be water repellant.
 6. The composite fabricof claim 5, wherein said outer fabric layer has a raised outer surfaceand a plain inner surface to which said barrier layer is adhered.
 7. Thecomposite fabric of claim 5, wherein said outer fabric is an essentiallyflat shell material.
 8. The composite fabric of claim 1, wherein saidouter layer of fabric is essentially formed of polyester.
 9. Thecomposite fabric of claim 1, wherein said barrier means includes asecond hydrophilic barrier layer disposed on and adhered to said otherof said outer surface of said inner layer of fabric and said outer layerof fabric, said first-mentioned and said second barrier layers beingadhered to each other.
 10. The composite fabric of claim 1, wherein saidinner layer of fabric is a raised surface knit fabric.
 11. The compositefabric of claim 1, wherein said inner layer of fabric is a circular weftknit fabric.
 12. The composite fabric of claim 1, wherein said barrierlayer is essentially non-porous.
 13. The composite fabric of claim 1,wherein said barrier layer is an essentially non-porous hydrophilicpolyurethane barrier layer.
 14. The composite fabric of claim 1, furtherincluding a discontinuous adhesive layer interposed between the other ofsaid inner surface of said inner layer of fabric and said outer layer offabric and said barrier layer.
 15. The composite fabric of claim 1,wherein at least one of said outer layer of fabric and said inner layerof fabric is selected from the group consisting of polyester, acrylic,cotton, nylon, wool, rayon or a combination thereof.
 16. The compositefabric of claim 1, wherein said outer layer of fabric and said innerlayer of fabric are both a stretchable material.
 17. The compositefabric of claim 1, wherein said outer layer of fabric and said innerlayer of fabric are both raised surface knit fabrics.
 18. The compositefabric of claim 9, wherein said first-mentioned and second barrierlayers are adhered to each other with the use of additional adhesives.19. The composite fabric of claim 1, wherein said inner layer of fabricis essentially formed of polyester.